US20020157864A1 - Multilayer wiring board and method of fabrication thereof - Google Patents

Multilayer wiring board and method of fabrication thereof Download PDF

Info

Publication number
US20020157864A1
US20020157864A1 US10/124,548 US12454802A US2002157864A1 US 20020157864 A1 US20020157864 A1 US 20020157864A1 US 12454802 A US12454802 A US 12454802A US 2002157864 A1 US2002157864 A1 US 2002157864A1
Authority
US
United States
Prior art keywords
wiring board
multilayer wiring
resin
thermosetting resin
thermosetting
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
US10/124,548
Other versions
US6759600B2 (en
Inventor
Toshinori Koyama
Noritaka Katagiri
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shinko Electric Industries Co Ltd
Original Assignee
Shinko Electric Industries Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Shinko Electric Industries Co Ltd filed Critical Shinko Electric Industries Co Ltd
Assigned to SHINKO ELECTRIC INDUSTRIES CO., LTD. reassignment SHINKO ELECTRIC INDUSTRIES CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KATAGIRI, NORITAKA, KOYAMA, TOSHINORI
Publication of US20020157864A1 publication Critical patent/US20020157864A1/en
Application granted granted Critical
Publication of US6759600B2 publication Critical patent/US6759600B2/en
Adjusted expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/46Manufacturing multilayer circuits
    • H05K3/4611Manufacturing multilayer circuits by laminating two or more circuit boards
    • H05K3/4626Manufacturing multilayer circuits by laminating two or more circuit boards characterised by the insulating layers or materials
    • H05K3/4632Manufacturing multilayer circuits by laminating two or more circuit boards characterised by the insulating layers or materials laminating thermoplastic or uncured resin sheets comprising printed circuits without added adhesive materials between the sheets
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/46Manufacturing multilayer circuits
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K1/00Printed circuits
    • H05K1/02Details
    • H05K1/03Use of materials for the substrate
    • H05K1/0313Organic insulating material
    • H05K1/0353Organic insulating material consisting of two or more materials, e.g. two or more polymers, polymer + filler, + reinforcement
    • H05K1/036Multilayers with layers of different types
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/46Manufacturing multilayer circuits
    • H05K3/4611Manufacturing multilayer circuits by laminating two or more circuit boards
    • H05K3/4614Manufacturing multilayer circuits by laminating two or more circuit boards the electrical connections between the circuit boards being made during lamination
    • H05K3/4617Manufacturing multilayer circuits by laminating two or more circuit boards the electrical connections between the circuit boards being made during lamination characterized by laminating only or mainly similar single-sided circuit boards
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2224/00Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
    • H01L2224/01Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
    • H01L2224/10Bump connectors; Manufacturing methods related thereto
    • H01L2224/15Structure, shape, material or disposition of the bump connectors after the connecting process
    • H01L2224/16Structure, shape, material or disposition of the bump connectors after the connecting process of an individual bump connector
    • H01L2224/161Disposition
    • H01L2224/16151Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive
    • H01L2224/16221Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked
    • H01L2224/16225Disposition the bump connector connecting between a semiconductor or solid-state body and an item not being a semiconductor or solid-state body, e.g. chip-to-substrate, chip-to-passive the body and the item being stacked the item being non-metallic, e.g. insulating substrate with or without metallisation
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L2924/00Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
    • H01L2924/15Details of package parts other than the semiconductor or other solid state devices to be connected
    • H01L2924/151Die mounting substrate
    • H01L2924/153Connection portion
    • H01L2924/1531Connection portion the connection portion being formed only on the surface of the substrate opposite to the die mounting surface
    • H01L2924/15311Connection portion the connection portion being formed only on the surface of the substrate opposite to the die mounting surface being a ball array, e.g. BGA
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/01Dielectrics
    • H05K2201/0137Materials
    • H05K2201/0141Liquid crystal polymer [LCP]
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/01Dielectrics
    • H05K2201/0137Materials
    • H05K2201/0154Polyimide
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/03Conductive materials
    • H05K2201/0332Structure of the conductor
    • H05K2201/0335Layered conductors or foils
    • H05K2201/0355Metal foils
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/03Conductive materials
    • H05K2201/0332Structure of the conductor
    • H05K2201/0388Other aspects of conductors
    • H05K2201/0394Conductor crossing over a hole in the substrate or a gap between two separate substrate parts
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2201/00Indexing scheme relating to printed circuits covered by H05K1/00
    • H05K2201/06Thermal details
    • H05K2201/068Thermal details wherein the coefficient of thermal expansion is important
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K2203/00Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
    • H05K2203/07Treatments involving liquids, e.g. plating, rinsing
    • H05K2203/0703Plating
    • H05K2203/0733Method for plating stud vias, i.e. massive vias formed by plating the bottom of a hole without plating on the walls
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05KPRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K3/00Apparatus or processes for manufacturing printed circuits
    • H05K3/40Forming printed elements for providing electric connections to or between printed circuits
    • H05K3/42Plated through-holes or plated via connections
    • H05K3/423Plated through-holes or plated via connections characterised by electroplating method
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49117Conductor or circuit manufacturing
    • Y10T29/49124On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/49126Assembling bases
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49117Conductor or circuit manufacturing
    • Y10T29/49124On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/4913Assembling to base an electrical component, e.g., capacitor, etc.
    • Y10T29/49144Assembling to base an electrical component, e.g., capacitor, etc. by metal fusion
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • Y10T29/49117Conductor or circuit manufacturing
    • Y10T29/49124On flat or curved insulated base, e.g., printed circuit, etc.
    • Y10T29/49155Manufacturing circuit on or in base
    • Y10T29/49165Manufacturing circuit on or in base by forming conductive walled aperture in base

Definitions

  • the present invention relates to a multilayer wiring board and a method of fabricating the same and, in particular, to a multilayer wiring board comprising a plurality of conductor patterns stacked with an insulating layer of a thermosetting resin interposed between adjacent conductor patterns, and a method of fabricating the multilayer wiring board.
  • These multilayer wiring boards are each formed by integrally stacking a plurality of resin sheets 100 of a thermosetting resin which exhibits the bonding properties by heat treatment at a predetermined temperature.
  • Each resin sheet 100 includes a thermosetting resin layer 102 capable of exhibiting the bonding properties by heat treatment at a predetermined temperature, a conductor pattern 104 formed on one surface of the thermosetting resin layer 102 , and at least a via 108 formed through the thermosetting resin layer 102 .
  • the via 108 has an end thereof connected to the conductor pattern 104 and the other end thereof exposed at a second surface of the thermosetting resin layer 102 .
  • the via 108 is formed of a recess 106 open to the second surface of the thermosetting resin layer 102 and having the bottom surface thereof exposed to the reverse surface of the conductor pattern 104 , which recess 106 is filled, by electroplating, with a solder adapted to melt at a temperature lower than the temperature at which the thermosetting resin layer 102 exhibits the bonding properties.
  • a plurality of the resin sheets 100 shown in FIG. 7A are stacked and heat treated at a temperature enabling the thermosetting resin layers 102 to exhibit the bonding properties, whereby the multilayer wiring board shown in FIG. 7B can be produced.
  • the conductor patterns 104 stacked in multiple layers are electrically connected to each other by the vias 108 .
  • the multilayer wiring board shown in FIG. 7B is configured to improve the dimensional and positional accuracy of the vias, etc. and can be easily reduced in thickness with the conductor patterns formed at a high density.
  • the resin sheets 100 constituting the multilayer wiring board shown in FIG. 7B are each substantially formed of a thermosetting resin and therefore thermally expand/contract to a greater degree than package members mounted thereon such as a semiconductor element. It has been found, therefore, that the improvement in the reliability of connection between the multilayer wiring board and the package members such as a semiconductor element mounted thereon is limited.
  • the multilayer wiring board In order to suppress the expansion/contraction of the multilayer wiring board, an attempt has been made to fabricate a multilayer wiring board using a resin sheet having arranged therein a reinforcing member composed of unwoven fabric such as glass cloth or organic fiber. Nevertheless, the multilayer wiring board finally produced by incorporating the reinforcing member of unwoven fabric such as glass cloth or organic fiber is found to increase in thickness undesirably, on the one hand, and cannot be easily formed with a fine via recess using a laser, on the other.
  • the object of the present invention is to provide a multilayer wiring board and a method of fabricating the same, which can improve the reliability of connection with the package members such as a semiconductor element mounted on the wiring board without using the reinforcing member composed of unwoven fabric such as glass cloth or organic fiber.
  • a resin sheet, with a conductor pattern formed on one surface thereof, comprising a pair of film-like thermosetting resin layers and a resin film having a lower coefficient of linear expansion than, and sandwiched between, the film-like thermosetting resin layers is thermally expanded/contracted to a lesser degree during the process of fabricating a multilayer wiring board, thereby making it possible to improve the reliability of connection between the resulting multilayer wiring board and the package members such as a semiconductor element.
  • a multilayer wiring board comprising a plurality of conductor patterns stacked with an insulating layer composed of a thermosetting resin interposed between adjacent conductor patterns, wherein the insulating layers each include a pair of film-like thermosetting resin layers and a resin film having a lower coefficient of linear expansion than, and sandwiched between, the thermosetting resin layers, and wherein the electrical connection between the stacked conductor patterns is established by vias formed through each insulating layer.
  • a method of fabricating a multilayer wiring board comprising a plurality of integrally-stacked resin sheets each having one surface thereof formed with a conductor pattern;
  • each of the resin sheets includes a pair of film-like thermosetting resin layers adapted to exhibit the bonding properties when heat treated at a predetermined temperature, a resin film having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers, a conductor pattern formed on one surface of the sandwich, and vias having an end thereof coupled to the reverse surface of the conductor pattern and the other end thereof exposed to a second surface of the sandwich,
  • thermosetting resin layers heat treating the resin sheets at a temperature enabling the thermosetting resin layers to exhibit the bonding properties thereby to integrate a plurality of the resin sheets.
  • a metal is filled by plating in each of the recesses, which are formed in the resin sheet and have the bottom thereof exposed to the reverse surface of the conductor pattern of the resin sheet, thereby forming vias with an end thereof coupled to the reverse surface of the conductor pattern and the other end thereof fixed at a predetermined portion of the conductor pattern of an adjacent resin sheet by a metal solder material or the like.
  • the vias and the conductor patterns can be connected securely to each other.
  • the via and the conductor pattern can be fixed to each other easily by forming a metal solder layer at the end of the via.
  • the metal solder material desirably has a melting point higher than the thermosetting temperature of the thermosetting resin.
  • the use of this metal solder material makes it possible to heat treat a plurality of resin sheets in stack in such a manner that the heat treatment temperature is increased to higher than the melting point of the metal solder material and then decreased to and held at the thermosetting temperature of the thermosetting resin for a predetermined length of time, or alternatively, the heat treatment temperature is increased to and held at the thermosetting temperature of the thermosetting resin for a predetermined length of time, and after the thermosetting resin layer is set, the temperature is increased to higher than the melting point of the metal solder material, followed by being decreased. In this way, the via and the conductor pattern can be connected positively to each other without causing any outflow of, or a void in, the metal solder material.
  • a resin film having a coefficient of linear expansion of not more than 20 ⁇ 10 ⁇ 6 /K at room temperature can be suitably used.
  • a multilayer wiring board comprising a plurality of resin sheets in a stack, each having a conductor pattern on one surface thereof, is fabricated.
  • Each resin sheet includes a pair of film-like thermosetting resin layers adapted to exhibit the bonding properties when heat treated at a predetermined temperature, and a resin film having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers. Even in the case where the resin sheets are heated during the fabrication process of the multilayer wiring board, therefore, the thermal expansion/contraction of the resin sheet can be reduced as compared with a resin sheet composed of a thermosetting resin layer alone.
  • the multilayer wiring board according to the invention therefore, the difference in thermal expansion/contraction between the wiring board and the package members such as the semiconductor elements can be reduced, thereby improving the reliability of connection between the semiconductor elements and the package members.
  • FIG. 1 is a partial sectional view showing an example of a multilayer wiring board according to the invention.
  • FIG. 2 illustrates a part of the process for fabricating the multilayer wiring board shown in FIG. 1.
  • FIGS. 3A to 3 F illustrate the fabrication process of the resin sheet shown in FIG. 2.
  • FIG. 4 is a partial sectional view showing the state of the second end of each via formed in the resin sheet shown in FIG. 2.
  • FIG. 5 is a graph showing a temperature profile for integrating, by heating, a plurality of the resin sheets in stack.
  • FIG. 6 is a graph showing another temperature profile for integrating, by heating, a plurality of the resin sheets in stack.
  • FIGS. 7A and 7B illustrate a conventional multilayer wiring board and a method of fabricating the same.
  • FIG. 8 illustrates a build-up multilayer wiring board fabricated by use of a multilayer wiring board according to the invention.
  • FIG. 9 illustrates a barrier layer, which may be formed prior to the formation of vias.
  • FIG. 10A illustrates the formation of a via using plated copper and solder
  • FIG. 10B illustrates the formation of a via using plated solder, on the barrier layer shown in FIG. 9.
  • the multilayer wiring board includes insulating layers 12 , each formed between adjacent layers of conductor patterns 10 stacked in multiple layers, and comprising a pair of film-like thermosetting resin layers composed of a thermosetting resin and a resin film 14 having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers.
  • the resin layer 12 is thus reinforced by the resin film 14 and is thermally expanded/contracted to a lesser degree, thereby making it possible to reduce the thermal expansion/contraction of the multilayer wiring board as a whole.
  • each insulating layer 12 The conductor patterns 10 formed on the first surface of each insulating layer 12 are electrically connected, by vias 16 formed through the insulating layer 12 , to the conductor patterns 10 of the upper and/or lower adjacent insulating layers 12 .
  • a first end of each via 16 is connected to the reverse surface of a conductor pattern 10 , and a second end thereof is fixed by a solder 18 constituting a metal solder material on the surface of the pad of another conductor pattern 10 .
  • solder 18 makes up a metal solder material this way, the second end of each via 16 and the pad surface can be connected securely to each other even in the presence of a gap between them.
  • thermosetting resin used for the multilayer wiring board shown in FIG. 1 is, for example, epoxy resin or polyphenylene ether resin.
  • the coefficient of linear expansion of the resin film 14 is desirably not more than 20 ⁇ 10 ⁇ 6 /K at room temperature, or more desirably between 2 ⁇ 10 ⁇ 6 and 4 ⁇ 10 ⁇ 6 /K.
  • the material of the resin film 14 meeting this requirement is, for example, aramid, liquid crystal polymer or polyimide.
  • the multilayer wiring board shown in FIG. 1 can be produced by integrally stacking a plurality of resin sheets 20 in the manner shown in FIG. 2.
  • the resin sheets 20 each include a pair of film-like thermosetting resin layers 22 composed of a thermosetting resin capable of exhibiting the bonding properties when heat treated at a predetermined temperature (hereinafter sometimes referred to as the B-type thermosetting resin), a resin film 14 having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers 22 , and a conductor pattern 10 formed on the first surface of the sandwich.
  • the resin sheet 20 has vias 16 piercing through the thermosetting resin layers 22 and the resin film 14 .
  • the via 16 has a first end connected to the reverse surface of the conductor pattern 10 (the surface of the conductor pattern 10 in contact with a thermosetting resin layer 22 ), and a second end exposed to the surface of the resin sheet 20 lacking the conductor pattern 10 .
  • a solder layer 24 is formed on the exposed end of the via 16 .
  • Each of the resin sheets 20 shown in FIG. 2 has through holes 36 for assuring alignment with another resin sheet.
  • This resin sheet 20 can be formed following the steps shown in FIG. 3.
  • a laminate film 34 is prepared (FIG. 3A).
  • This laminate film 34 includes a pair of thermosetting resin layers 22 about 50 ⁇ m thick composed of the B-type thermosetting resin, a resin film 14 about 4.5 to 9 ⁇ m thick having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers 22 , and a pair of cover films 26 constituting protective films bonded to the two outer surfaces of the laminate film 34 .
  • thermosetting resin layer exhibiting the bonding properties at room temperature is coated to form a thermosetting resin layer on each of the two surfaces of the resin film 14 , after which the thermosetting resin layers 22 are semi-set by heat treatment at a predetermined temperature.
  • the semi-set thermosetting resin layers 22 do not exhibit the bonding properties at room temperature but do by being heated to higher than the temperature of the heat treatment conducted earlier for producing the semi-set state.
  • a plurality of through holes 28 are formed at predetermined portions of the laminate film 34 by a laser beam (FIG. 3B).
  • the laser beam can be produced by carbon dioxide laser or a UV laser.
  • the laminate film 34 has no reinforcing member, such as glass cloth, difficult to cut by the laser and therefore can be easily formed with the fine through holes 28 by a widely-used laser.
  • the cover film 26 on a first surface of the laminate film 34 is removed and a copper foil 30 about 18 ⁇ m thick is bonded on it (FIG. 3C).
  • the through holes 28 each having an end thereof covered with the reverse surface of the cover film 26 , and recesses 32 , are formed.
  • the cover film 26 on the second surface of the laminate film 34 is removed, and the electroplating is conducted with the copper foil 30 as a power supply layer so that copper metal is filled in the recess 32 thereby to form vias 16 (FIG. 3D).
  • the vias 16 each have an end thereof connected to the reverse surface of the copper foil 30 , and the other end thereof exposed to the outer surface of the thermosetting resin layer 22 .
  • solder layer 24 is formed by electroplating with the copper foil 30 acting as a power supply layer (FIG. 3E).
  • the solder layer 24 is formed of a solder having a melting point higher than the thermosetting temperature of the thermosetting resin constituting the thermosetting resin layers 22 .
  • the solder usable for the solder layer 24 is a solder alloy (a solder composed of, for example, Sn—Pb, Sn—Ag or Sn—Ag—Cu alloy) or tin (Sn).
  • a solder alloy free of lead (such as Sn—Ag or Sn—Ag—Cu) can be suitably used.
  • the conductor pattern 10 is formed from the copper foil 30 by photolithography technique or the like to thereby form a resin sheet 20 (FIG. 3F).
  • the vias 16 may be formed by filling the recesses 32 with a metallic solder.
  • the metallic solder is filled in the recesses 32 by electroplating using the copper foil 30 as a power supply layer.
  • the metallic solder can be selected from the solder materials referred to above. Using a solder as the material to form the vias 16 is advantageous in that it simplifies the process for forming the vias 16 compared to the formation of the vias 16 using copper plating and subsequent solder plating.
  • the barrier layer 38 can be formed by electroplating the copper foil 30 within the recess 32 with a metal material, such as nickel, using the copper foil 30 as a power supply layer. During the etching of the copper foil 30 for the formation of the conductor pattern 10 , the material of the vias 16 can be etched. The barrier layer 38 prevents the via material from being etched by an etchant for copper. For this purpose, it is sufficient for the barrier layer 38 to be formed of a metal material, which is resistant to an etchant for copper used, in a thickness of several micrometers.
  • the recess 32 is filled with plated copper 52 and plated solder 54 , as shown in FIG. 10A, or is filled with plated solder 54 alone, as shown in FIG. 10B, to form the vias as described above.
  • a plurality of resin sheets 20 formed in this way are stacked as shown in FIG. 2 and integrated by being heated to a predetermined temperature.
  • the exposed end of each via 16 on the second surface of the resin sheet 20 is brought into contact with a predetermined portion of the conductor pattern 10 formed on another resin sheet 20 by desirably regulating the electroplating conditions, such as the plating time, in such a manner as to make the exposed end of the via 16 project somewhat from the second end surface of the resin sheet 20 , as shown in FIG. 4.
  • the electroplating conditions are regulated to assure as uniform a height, of the vias 16 , as possible.
  • the heating ambience for heating a plurality of the resin sheets 20 in a stack is increased to temperature A not lower than the melting point of the solder of the solder layer 24 , and then decreased to and held at the setting temperature B of the thermosetting resin constituting the thermosetting resin layers 22 of the resin sheet 20 .
  • This temperature profile makes it possible to bond the forward end of each via 16 , to a predetermined portion of the conductor pattern 10 by the solder 18 (FIG. 1), as the solder of the solder layer 24 is melted and solidified before the thermosetting resin of the thermosetting resin layers 22 is completely set.
  • the solder layer 24 is desirably formed of the solder having a melting point of at least 200° C. In the case where the solder layer 24 is formed of eutectic solder having a melting point of about 180° C., the solder may be melted and flow out, or create a void in the bonding surface, when thermally setting the epoxy resin.
  • the temperature is increased to and held at the setting level B of the thermosetting resin constituting the thermosetting resin layers 22 of the resin sheet 20 for a predetermined length of time, after which the temperature is decreased to the level A not lower than the melting point of the solder of the solder layer 24 .
  • the temperature profile shown in FIG. 6 makes it possible to melt and solidify the solder of the solder layer 4 after the thermosetting resin of the thermosetting resin layers 22 is completely set and, therefore, the forward end of the via 16 can be bonded with a predetermined portion of the conductor pattern 10 with a satisfactory appearance of the solder junction.
  • each via 16 and a predetermined portion of the conductor pattern 10 can be bonded to each other by the solder 18 without causing any solder outflow or a junction void.
  • the preflux (not shown) is preferably coated on the surface of the conductor patterns 10 in order to prevent oxidization of the surface of the conductor patterns 10 (FIG. 1) composed of copper and improve the solder wettability for soldering the package members including a semiconductor element.
  • a water-soluble preflux is desirable for this purpose, as it can be left selectively on the metal by washing in water after being coated on the metal conductor patterns 10 .
  • the multilayer wiring board according to the invention can be used as a core member for fabricating a build-up multilayer wiring board by stacking a conductor pattern on each of the two surfaces of the core member according to the well-known build-up method.
  • FIG. 8 shows an example of a build-up multilayer wiring board fabricated by the build-up method using the multilayer wiring board according to the invention as a core member.
  • the build-up multilayer wiring board 40 shown in FIG. 8 comprises a core substrate 41 making up a multilayer wiring board according to the invention formed using the resin sheets each including the thermosetting resin layers and the resin film having a low coefficient of linear expansion, and build-up layers 42 a , 42 b formed on the two surfaces, respectively, of the core substrate 41 by the build-up method.
  • the core substrate 41 may have construction as shown is FIG. 1.
  • the build-up layers 42 a , 42 b each include a plurality of conductor patterns 43 a , 43 b stacked with insulating layers.
  • the conductor patterns 43 a on the upper surface side and the conductor patterns 43 b on the lower surface side of the core substrate 41 are connected to each other by through holes 45 formed through the core substrate 41 .
  • This build-up multilayer wiring board 40 can be used with the package parts such as a semiconductor chip 44 mounted on the upper surface thereof and a package substrate (not shown) on which the multilayer wiring board 40 is mounted through solder bumps 46 on the lower surface thereof.
  • the conductor patterns can be formed in high density on the build-up multilayer wiring board finally fabricated by using the multilayer wiring board according to the invention as a core member.
  • the difference of thermal contraction with the package members such as a semiconductor element can be minimized for an improved reliability of connection with the package members. Consequently, the reliability can be greatly improved of the semiconductor device, etc. produced by packaging a semiconductor element, etc. on a multilayer wiring board according to the invention or a different multilayer wiring board fabricated based on a multilayer wiring board, according to the invention, as a core member.

Abstract

A multilayer wiring board comprising a plurality of conductor patterns stacked with an insulating layer composed of a thermosetting resin interposed between adjacent conductor patterns, wherein the insulating layers are each formed of a pair of film-like thermosetting resin layers and a resin film having a lower coefficient of linear expansion than, and sandwiched between, the thermosetting resin layers, and wherein the electrical connection between the stacked conductor patterns is established by vias formed through the insulating layers. A method of fabricating such a multilayer wiring board is also disclosed.

Description

    BACKGROUND OF THE INVENTION
  • 1. Field of the Invention [0001]
  • The present invention relates to a multilayer wiring board and a method of fabricating the same and, in particular, to a multilayer wiring board comprising a plurality of conductor patterns stacked with an insulating layer of a thermosetting resin interposed between adjacent conductor patterns, and a method of fabricating the multilayer wiring board. [0002]
  • 2. Description of the Related Art [0003]
  • Various multilayer wiring boards each comprising a plurality of conductor patterns stacked with an insulating layer of a thermosetting resin interposed between adjacent conductor patterns are proposed in Japanese Unexamined Patent Publication No. 10-190232, etc. [0004]
  • These multilayer wiring boards, as shown in FIG. 7A, are each formed by integrally stacking a plurality of [0005] resin sheets 100 of a thermosetting resin which exhibits the bonding properties by heat treatment at a predetermined temperature.
  • Each [0006] resin sheet 100 includes a thermosetting resin layer 102 capable of exhibiting the bonding properties by heat treatment at a predetermined temperature, a conductor pattern 104 formed on one surface of the thermosetting resin layer 102, and at least a via 108 formed through the thermosetting resin layer 102. The via 108 has an end thereof connected to the conductor pattern 104 and the other end thereof exposed at a second surface of the thermosetting resin layer 102. The via 108 is formed of a recess 106 open to the second surface of the thermosetting resin layer 102 and having the bottom surface thereof exposed to the reverse surface of the conductor pattern 104, which recess 106 is filled, by electroplating, with a solder adapted to melt at a temperature lower than the temperature at which the thermosetting resin layer 102 exhibits the bonding properties.
  • A plurality of the [0007] resin sheets 100 shown in FIG. 7A are stacked and heat treated at a temperature enabling the thermosetting resin layers 102 to exhibit the bonding properties, whereby the multilayer wiring board shown in FIG. 7B can be produced. In the multilayer wiring board shown in FIG. 7A, the conductor patterns 104 stacked in multiple layers are electrically connected to each other by the vias 108.
  • The multilayer wiring board shown in FIG. 7B is configured to improve the dimensional and positional accuracy of the vias, etc. and can be easily reduced in thickness with the conductor patterns formed at a high density. [0008]
  • The [0009] resin sheets 100 constituting the multilayer wiring board shown in FIG. 7B, however, are each substantially formed of a thermosetting resin and therefore thermally expand/contract to a greater degree than package members mounted thereon such as a semiconductor element. It has been found, therefore, that the improvement in the reliability of connection between the multilayer wiring board and the package members such as a semiconductor element mounted thereon is limited.
  • In order to suppress the expansion/contraction of the multilayer wiring board, an attempt has been made to fabricate a multilayer wiring board using a resin sheet having arranged therein a reinforcing member composed of unwoven fabric such as glass cloth or organic fiber. Nevertheless, the multilayer wiring board finally produced by incorporating the reinforcing member of unwoven fabric such as glass cloth or organic fiber is found to increase in thickness undesirably, on the one hand, and cannot be easily formed with a fine via recess using a laser, on the other. [0010]
  • SUMMARY OF THE INVENTION
  • Accordingly, the object of the present invention is to provide a multilayer wiring board and a method of fabricating the same, which can improve the reliability of connection with the package members such as a semiconductor element mounted on the wiring board without using the reinforcing member composed of unwoven fabric such as glass cloth or organic fiber. [0011]
  • As the result of studying a solution to the aforementioned problem, the present inventor has developed this invention based on the discovery of the fact that a resin sheet, with a conductor pattern formed on one surface thereof, comprising a pair of film-like thermosetting resin layers and a resin film having a lower coefficient of linear expansion than, and sandwiched between, the film-like thermosetting resin layers is thermally expanded/contracted to a lesser degree during the process of fabricating a multilayer wiring board, thereby making it possible to improve the reliability of connection between the resulting multilayer wiring board and the package members such as a semiconductor element. [0012]
  • According to one aspect of the invention, there is provided a multilayer wiring board comprising a plurality of conductor patterns stacked with an insulating layer composed of a thermosetting resin interposed between adjacent conductor patterns, wherein the insulating layers each include a pair of film-like thermosetting resin layers and a resin film having a lower coefficient of linear expansion than, and sandwiched between, the thermosetting resin layers, and wherein the electrical connection between the stacked conductor patterns is established by vias formed through each insulating layer. [0013]
  • According to another aspect of the invention, there is provided a method of fabricating a multilayer wiring board comprising a plurality of integrally-stacked resin sheets each having one surface thereof formed with a conductor pattern; [0014]
  • wherein each of the resin sheets includes a pair of film-like thermosetting resin layers adapted to exhibit the bonding properties when heat treated at a predetermined temperature, a resin film having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers, a conductor pattern formed on one surface of the sandwich, and vias having an end thereof coupled to the reverse surface of the conductor pattern and the other end thereof exposed to a second surface of the sandwich, [0015]
  • the method comprising the steps of: [0016]
  • stacking a plurality of the resin sheets in such a manner that the exposed end of the via of each resin sheet is in contact with a predetermined portion of the conductor pattern of an adjacent resin sheet; and [0017]
  • heat treating the resin sheets at a temperature enabling the thermosetting resin layers to exhibit the bonding properties thereby to integrate a plurality of the resin sheets. [0018]
  • According to this invention, a metal is filled by plating in each of the recesses, which are formed in the resin sheet and have the bottom thereof exposed to the reverse surface of the conductor pattern of the resin sheet, thereby forming vias with an end thereof coupled to the reverse surface of the conductor pattern and the other end thereof fixed at a predetermined portion of the conductor pattern of an adjacent resin sheet by a metal solder material or the like. In this way, the vias and the conductor patterns can be connected securely to each other. [0019]
  • The via and the conductor pattern can be fixed to each other easily by forming a metal solder layer at the end of the via. [0020]
  • The metal solder material desirably has a melting point higher than the thermosetting temperature of the thermosetting resin. The use of this metal solder material makes it possible to heat treat a plurality of resin sheets in stack in such a manner that the heat treatment temperature is increased to higher than the melting point of the metal solder material and then decreased to and held at the thermosetting temperature of the thermosetting resin for a predetermined length of time, or alternatively, the heat treatment temperature is increased to and held at the thermosetting temperature of the thermosetting resin for a predetermined length of time, and after the thermosetting resin layer is set, the temperature is increased to higher than the melting point of the metal solder material, followed by being decreased. In this way, the via and the conductor pattern can be connected positively to each other without causing any outflow of, or a void in, the metal solder material. [0021]
  • A resin film having a coefficient of linear expansion of not more than 20×10[0022] −6/K at room temperature can be suitably used.
  • According to this invention, a multilayer wiring board comprising a plurality of resin sheets in a stack, each having a conductor pattern on one surface thereof, is fabricated. Each resin sheet includes a pair of film-like thermosetting resin layers adapted to exhibit the bonding properties when heat treated at a predetermined temperature, and a resin film having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers. Even in the case where the resin sheets are heated during the fabrication process of the multilayer wiring board, therefore, the thermal expansion/contraction of the resin sheet can be reduced as compared with a resin sheet composed of a thermosetting resin layer alone. [0023]
  • With the multilayer wiring board according to the invention, therefore, the difference in thermal expansion/contraction between the wiring board and the package members such as the semiconductor elements can be reduced, thereby improving the reliability of connection between the semiconductor elements and the package members.[0024]
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a partial sectional view showing an example of a multilayer wiring board according to the invention. [0025]
  • FIG. 2 illustrates a part of the process for fabricating the multilayer wiring board shown in FIG. 1. [0026]
  • FIGS. 3A to [0027] 3F illustrate the fabrication process of the resin sheet shown in FIG. 2.
  • FIG. 4 is a partial sectional view showing the state of the second end of each via formed in the resin sheet shown in FIG. 2. [0028]
  • FIG. 5 is a graph showing a temperature profile for integrating, by heating, a plurality of the resin sheets in stack. [0029]
  • FIG. 6 is a graph showing another temperature profile for integrating, by heating, a plurality of the resin sheets in stack. [0030]
  • FIGS. 7A and 7B illustrate a conventional multilayer wiring board and a method of fabricating the same. [0031]
  • FIG. 8 illustrates a build-up multilayer wiring board fabricated by use of a multilayer wiring board according to the invention. [0032]
  • FIG. 9 illustrates a barrier layer, which may be formed prior to the formation of vias. [0033]
  • FIG. 10A illustrates the formation of a via using plated copper and solder, and FIG. 10B illustrates the formation of a via using plated solder, on the barrier layer shown in FIG. 9.[0034]
  • DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • An example of a multilayer wiring board according to the invention is shown in a partial sectional view of FIG. 1. In the drawing, the multilayer wiring board includes [0035] insulating layers 12, each formed between adjacent layers of conductor patterns 10 stacked in multiple layers, and comprising a pair of film-like thermosetting resin layers composed of a thermosetting resin and a resin film 14 having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers. The resin layer 12 is thus reinforced by the resin film 14 and is thermally expanded/contracted to a lesser degree, thereby making it possible to reduce the thermal expansion/contraction of the multilayer wiring board as a whole.
  • The [0036] conductor patterns 10 formed on the first surface of each insulating layer 12 are electrically connected, by vias 16 formed through the insulating layer 12, to the conductor patterns 10 of the upper and/or lower adjacent insulating layers 12.
  • A first end of each [0037] via 16 is connected to the reverse surface of a conductor pattern 10, and a second end thereof is fixed by a solder 18 constituting a metal solder material on the surface of the pad of another conductor pattern 10. By using the solder 18 making up a metal solder material this way, the second end of each via 16 and the pad surface can be connected securely to each other even in the presence of a gap between them.
  • The thermosetting resin used for the multilayer wiring board shown in FIG. 1 is, for example, epoxy resin or polyphenylene ether resin. [0038]
  • The coefficient of linear expansion of the [0039] resin film 14 is desirably not more than 20×10−6/K at room temperature, or more desirably between 2×10−6 and 4×10−6/K. The material of the resin film 14 meeting this requirement is, for example, aramid, liquid crystal polymer or polyimide.
  • The multilayer wiring board shown in FIG. 1 can be produced by integrally stacking a plurality of [0040] resin sheets 20 in the manner shown in FIG. 2. The resin sheets 20 each include a pair of film-like thermosetting resin layers 22 composed of a thermosetting resin capable of exhibiting the bonding properties when heat treated at a predetermined temperature (hereinafter sometimes referred to as the B-type thermosetting resin), a resin film 14 having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers 22, and a conductor pattern 10 formed on the first surface of the sandwich.
  • The [0041] resin sheet 20 has vias 16 piercing through the thermosetting resin layers 22 and the resin film 14. The via 16 has a first end connected to the reverse surface of the conductor pattern 10 (the surface of the conductor pattern 10 in contact with a thermosetting resin layer 22), and a second end exposed to the surface of the resin sheet 20 lacking the conductor pattern 10. A solder layer 24 is formed on the exposed end of the via 16.
  • Each of the [0042] resin sheets 20 shown in FIG. 2 has through holes 36 for assuring alignment with another resin sheet.
  • This [0043] resin sheet 20 can be formed following the steps shown in FIG. 3. First, a laminate film 34 is prepared (FIG. 3A). This laminate film 34 includes a pair of thermosetting resin layers 22 about 50 μm thick composed of the B-type thermosetting resin, a resin film 14 about 4.5 to 9 μm thick having a lower coefficient of linear expansion than and sandwiched between the thermosetting resin layers 22, and a pair of cover films 26 constituting protective films bonded to the two outer surfaces of the laminate film 34.
  • In forming the [0044] laminate film 34, a thermosetting resin layer exhibiting the bonding properties at room temperature is coated to form a thermosetting resin layer on each of the two surfaces of the resin film 14, after which the thermosetting resin layers 22 are semi-set by heat treatment at a predetermined temperature. The semi-set thermosetting resin layers 22 do not exhibit the bonding properties at room temperature but do by being heated to higher than the temperature of the heat treatment conducted earlier for producing the semi-set state.
  • A plurality of through [0045] holes 28 are formed at predetermined portions of the laminate film 34 by a laser beam (FIG. 3B). The laser beam can be produced by carbon dioxide laser or a UV laser. The laminate film 34 has no reinforcing member, such as glass cloth, difficult to cut by the laser and therefore can be easily formed with the fine through holes 28 by a widely-used laser.
  • The [0046] cover film 26 on a first surface of the laminate film 34 is removed and a copper foil 30 about 18 μm thick is bonded on it (FIG. 3C). As a result, the through holes 28, each having an end thereof covered with the reverse surface of the cover film 26, and recesses 32, are formed.
  • The [0047] cover film 26 on the second surface of the laminate film 34 is removed, and the electroplating is conducted with the copper foil 30 as a power supply layer so that copper metal is filled in the recess 32 thereby to form vias 16 (FIG. 3D). The vias 16 each have an end thereof connected to the reverse surface of the copper foil 30, and the other end thereof exposed to the outer surface of the thermosetting resin layer 22.
  • Further, at the exposed end of each via [0048] 16, a solder layer 24 about 2 to 6 μm thick is formed by electroplating with the copper foil 30 acting as a power supply layer (FIG. 3E). The solder layer 24 is formed of a solder having a melting point higher than the thermosetting temperature of the thermosetting resin constituting the thermosetting resin layers 22.
  • The solder usable for the [0049] solder layer 24 is a solder alloy (a solder composed of, for example, Sn—Pb, Sn—Ag or Sn—Ag—Cu alloy) or tin (Sn). A solder alloy free of lead (such as Sn—Ag or Sn—Ag—Cu) can be suitably used.
  • After that, the [0050] conductor pattern 10 is formed from the copper foil 30 by photolithography technique or the like to thereby form a resin sheet 20 (FIG. 3F).
  • The [0051] vias 16 may be formed by filling the recesses 32 with a metallic solder. In this case, the metallic solder is filled in the recesses 32 by electroplating using the copper foil 30 as a power supply layer. The metallic solder can be selected from the solder materials referred to above. Using a solder as the material to form the vias 16 is advantageous in that it simplifies the process for forming the vias 16 compared to the formation of the vias 16 using copper plating and subsequent solder plating.
  • Prior to the formation of the [0052] vias 16, it is also possible to form a barrier layer 38 on the copper foil 30 within the recesses 32, as shown in FIG. 9. The barrier layer 38 can be formed by electroplating the copper foil 30 within the recess 32 with a metal material, such as nickel, using the copper foil 30 as a power supply layer. During the etching of the copper foil 30 for the formation of the conductor pattern 10, the material of the vias 16 can be etched. The barrier layer 38 prevents the via material from being etched by an etchant for copper. For this purpose, it is sufficient for the barrier layer 38 to be formed of a metal material, which is resistant to an etchant for copper used, in a thickness of several micrometers.
  • Subsequently to the formation of the [0053] barrier layer 38, the recess 32 is filled with plated copper 52 and plated solder 54, as shown in FIG. 10A, or is filled with plated solder 54 alone, as shown in FIG. 10B, to form the vias as described above.
  • A plurality of [0054] resin sheets 20 formed in this way are stacked as shown in FIG. 2 and integrated by being heated to a predetermined temperature.
  • In stacking and integrating a plurality of the [0055] resin sheets 20, the exposed end of each via 16 on the second surface of the resin sheet 20 is brought into contact with a predetermined portion of the conductor pattern 10 formed on another resin sheet 20 by desirably regulating the electroplating conditions, such as the plating time, in such a manner as to make the exposed end of the via 16 project somewhat from the second end surface of the resin sheet 20, as shown in FIG. 4. In the case where the exposed end of each via 16 is projected somewhat from the second end surface of the resin sheet 20 as shown in FIG. 4, the electroplating conditions are regulated to assure as uniform a height, of the vias 16, as possible.
  • For integrating by heating a plurality of the [0056] resin sheets 20 in stack, it is desirable to conduct the heat treatment using a vacuum-thermal press according to the temperature profile shown in FIG. 5 while at the same time removing the gas generated by the heat treatment from the laminate as quickly as possible.
  • In the temperature profile shown in FIG. 5, the heating ambience for heating a plurality of the [0057] resin sheets 20 in a stack is increased to temperature A not lower than the melting point of the solder of the solder layer 24, and then decreased to and held at the setting temperature B of the thermosetting resin constituting the thermosetting resin layers 22 of the resin sheet 20. This temperature profile makes it possible to bond the forward end of each via 16, to a predetermined portion of the conductor pattern 10 by the solder 18 (FIG. 1), as the solder of the solder layer 24 is melted and solidified before the thermosetting resin of the thermosetting resin layers 22 is completely set.
  • In the case where epoxy resin having a thermosetting temperature of 180° C. is used for the thermosetting resin layers [0058] 22, for example, the solder layer 24 is desirably formed of the solder having a melting point of at least 200° C. In the case where the solder layer 24 is formed of eutectic solder having a melting point of about 180° C., the solder may be melted and flow out, or create a void in the bonding surface, when thermally setting the epoxy resin.
  • While integrating by heating a plurality of the [0059] resin sheets 20 in stack, it is also possible to bond the forward end of each via 16 to a predetermined portion of the conductor pattern 10 using the solder 18 (FIG. 1) without causing any solder outflow or creating a void in the bonding surface, by conducting the heat treatment according to the temperature profile shown in FIG. 6.
  • In the temperature profile shown in FIG. 6, the temperature is increased to and held at the setting level B of the thermosetting resin constituting the thermosetting resin layers [0060] 22 of the resin sheet 20 for a predetermined length of time, after which the temperature is decreased to the level A not lower than the melting point of the solder of the solder layer 24. The temperature profile shown in FIG. 6 makes it possible to melt and solidify the solder of the solder layer 4 after the thermosetting resin of the thermosetting resin layers 22 is completely set and, therefore, the forward end of the via 16 can be bonded with a predetermined portion of the conductor pattern 10 with a satisfactory appearance of the solder junction.
  • As described above, according to the temperature profiles shown in FIGS. 5 and 6, the forward end of each via [0061] 16 and a predetermined portion of the conductor pattern 10 can be bonded to each other by the solder 18 without causing any solder outflow or a junction void. This indicates that the heat treatment is effectively conducted along a temperature profile which precludes the possibility of the protracted simultaneous proceeding of the setting of the thermosetting resin layer 22 and the melting of the solder layer 4.
  • After integrating, by heating, a plurality of the [0062] resin sheets 20 in a stack, the preflux (not shown) is preferably coated on the surface of the conductor patterns 10 in order to prevent oxidization of the surface of the conductor patterns 10 (FIG. 1) composed of copper and improve the solder wettability for soldering the package members including a semiconductor element. A water-soluble preflux is desirable for this purpose, as it can be left selectively on the metal by washing in water after being coated on the metal conductor patterns 10.
  • The multilayer wiring board according to the invention shown in FIG. 1, as described above, even if heated for mounting the package members including a semiconductor element by soldering or the like, is thermally expanded/contracted to a minimum degree because the thermosetting resin layers making up each insulating [0063] layer 12 are reinforced by the resin film 14 having a low coefficient of linear expansion. As a result, the multilayer wiring board according to the invention has a smaller difference of thermal contraction with the package members such as a semiconductor element and thus a higher reliability of connection with the package members.
  • The multilayer wiring board according to the invention can be used as a core member for fabricating a build-up multilayer wiring board by stacking a conductor pattern on each of the two surfaces of the core member according to the well-known build-up method. FIG. 8 shows an example of a build-up multilayer wiring board fabricated by the build-up method using the multilayer wiring board according to the invention as a core member. The build-up [0064] multilayer wiring board 40 shown in FIG. 8 comprises a core substrate 41 making up a multilayer wiring board according to the invention formed using the resin sheets each including the thermosetting resin layers and the resin film having a low coefficient of linear expansion, and build-up layers 42 a, 42 b formed on the two surfaces, respectively, of the core substrate 41 by the build-up method. The core substrate 41 may have construction as shown is FIG. 1. The build-up layers 42 a, 42 b each include a plurality of conductor patterns 43 a, 43 b stacked with insulating layers. The conductor patterns 43 a on the upper surface side and the conductor patterns 43 b on the lower surface side of the core substrate 41 are connected to each other by through holes 45 formed through the core substrate 41. This build-up multilayer wiring board 40 can be used with the package parts such as a semiconductor chip 44 mounted on the upper surface thereof and a package substrate (not shown) on which the multilayer wiring board 40 is mounted through solder bumps 46 on the lower surface thereof.
  • As described above, the conductor patterns can be formed in high density on the build-up multilayer wiring board finally fabricated by using the multilayer wiring board according to the invention as a core member. [0065]
  • With the multilayer wiring board according to the invention, the difference of thermal contraction with the package members such as a semiconductor element can be minimized for an improved reliability of connection with the package members. Consequently, the reliability can be greatly improved of the semiconductor device, etc. produced by packaging a semiconductor element, etc. on a multilayer wiring board according to the invention or a different multilayer wiring board fabricated based on a multilayer wiring board, according to the invention, as a core member. [0066]

Claims (15)

1. A multilayer wiring board comprising a plurality of conductor patterns stacked with an insulating layer composed of a thermosetting resin interposed between adjacent conductor patterns,
wherein the insulating layers are each formed of a pair of film-like thermosetting resin layers and a resin film having a lower coefficient of linear expansion than, and sandwiched between, the thermosetting resin layers, and
wherein the electrical connection between the stacked conductor patterns is established by vias formed through the insulating layers.
2. A multilayer wiring board according to claim 1, wherein each said via has an end thereof coupled directly to a conductor pattern and the other end thereof fixed to another conductor pattern by a metal solder material.
3. A multilayer wiring board according to claim 2,
wherein said metal solder material has a melting point higher than the thermosetting temperature of said thermosetting resin.
4. A multilayer wiring board according to claim 3,
wherein said metal solder material is a selected one of a tin solder and a lead-free tin alloy solder.
5. A multilayer wiring board according to claim 1,
wherein the coefficient of linear expansion of said resin film at room temperature is not more than 20×10−6/K.
6. A method of fabricating a multilayer wiring board comprising a plurality of integrally-stacked resin sheets each having one surface thereof formed with a conductor pattern;
wherein each of the resin sheets includes a pair of film-like thermosetting resin layers adapted to exhibit the bonding properties when heat treated at a predetermined temperature, a resin film having a lower coefficient of linear expansion than, and sandwiched between, the thermosetting resin layers, a conductor pattern formed on one surface of the sandwich, and a plurality of vias each having an end thereof coupled to the reverse surface of the conductor pattern and the other end thereof exposed to the other surface of the sandwich,
the method comprising the steps of:
stacking a plurality of the resin sheets in such a manner that the exposed end of each of the vias of each resin sheet is in contact with a predetermined portion of the conductor pattern of an adjacent resin sheet; and
heat treating the resin sheets at a temperature enabling the thermosetting resin layers to exhibit the bonding properties thereby to integrate a plurality of said resin sheets.
7. A method of fabricating a multilayer wiring board according to claim 6,
wherein said vias are each formed in said resin sheet by filling a metal by plating in a recess with the bottom thereof exposed to the reverse surface of said conductor pattern, and
wherein an end of said via is coupled to the reverse surface of said conductor pattern, and the other end thereof is fixed by a metal solder to a predetermined portion of the conductor pattern of an adjacent resin sheet.
8. A method of fabricating a multilayer wiring board according to claim 7,
wherein said metal solder material is a selected one of tin solder and lead-free tin alloy.
9. A method of fabricating a multilayer wiring board according to claim 7,
wherein a metal solder material layer is formed at the other end of said via before fixing the other end of said via to the conductor pattern of an adjacent resin sheet by the metal solder material.
10. A method of fabricating a multilayer wiring board according to claim 7,
wherein said metal solder material has a melting point higher than the thermosetting temperature of said thermosetting resin, and
wherein a plurality of said resin sheets in a stack are integrated by heat treatment in such a manner that the heat treatment temperature is increased to not lower than the melting point of said metal solder material and decreased to and held at the thermosetting temperature of said thermosetting resin for a predetermined length of time thereby to set said thermosetting resin layers.
11. A method of fabricating a multilayer wiring board according to claim 9,
wherein said metal solder material has a melting point higher than the thermosetting temperature of said thermosetting resin, and
wherein a plurality of said resin sheets in a stack are integrated by heat treatment in such a manner that the heat treatment temperature is increased to not lower than the melting point of said metal solder material and decreased to and held at the thermosetting temperature of said thermosetting resin for a predetermined length of time thereby to set said thermosetting resin layer.
12. A method of fabricating a multilayer wiring board according to claim 7,
wherein said metal solder material has a melting point higher than the thermosetting temperature of said thermosetting resin, and
wherein a plurality of said resin sheets in a stack are integrated by heat treatment in such a manner that the heat treatment temperature is increased to and held at the thermosetting temperature of said thermosetting resin for a predetermined length of time, and is increased, upon solidification of the thermosetting resin layers, to not lower than the melting point of said metal solder material.
13. A method of fabricating a multilayer wiring board according to claim 9,
wherein said metal solder material has a melting point higher than the thermosetting temperature of said thermosetting resin, and
wherein a plurality of said resin sheets in a stack are integrated by heat treatment in such a manner that the heat treatment temperature is increased to and held at the thermosetting temperature of said thermosetting resin for a predetermined length of time, and is increased, upon solidification of the thermosetting resin layers, to not lower than the melting point of said metal solder material.
14. A method of fabricating a multilayer wiring board according to claim 6,
wherein the coefficient of linear expansion of said resin film is not more than 20×10−6/K.
15. A multilayer wiring board comprising the multilayer wiring board, according to claim 1, as a core member and a plurality of conductor patterns formed on the two surfaces of said core member, respectively, along with an insulation layer interposed between adjacent conductor patterns.
US10/124,548 2001-04-27 2002-04-17 Multilayer wiring board and method of fabrication thereof Expired - Lifetime US6759600B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2001-131287(PAT. 2001-04-27
JP2001131287 2001-04-27
JP2001-131287 2001-04-27

Publications (2)

Publication Number Publication Date
US20020157864A1 true US20020157864A1 (en) 2002-10-31
US6759600B2 US6759600B2 (en) 2004-07-06

Family

ID=18979497

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/124,548 Expired - Lifetime US6759600B2 (en) 2001-04-27 2002-04-17 Multilayer wiring board and method of fabrication thereof

Country Status (3)

Country Link
US (1) US6759600B2 (en)
KR (1) KR20020083485A (en)
TW (1) TW538663B (en)

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040000425A1 (en) * 2002-06-26 2004-01-01 White George E. Methods for fabricating three-dimensional all organic interconnect structures
US20050011670A1 (en) * 2002-12-19 2005-01-20 Endicott Interconnect Technologies, Inc Circuitized substrate assembly and method of making same
US20060017152A1 (en) * 2004-07-08 2006-01-26 White George E Heterogeneous organic laminate stack ups for high frequency applications
US20080000874A1 (en) * 2006-07-03 2008-01-03 Matsushita Electric Industrial Co., Ltd. Printed wiring board and method of manufacturing the same
US20080036668A1 (en) * 2006-08-09 2008-02-14 White George E Systems and Methods for Integrated Antennae Structures in Multilayer Organic-Based Printed Circuit Devices
US7439840B2 (en) 2006-06-27 2008-10-21 Jacket Micro Devices, Inc. Methods and apparatuses for high-performing multi-layer inductors
US7489914B2 (en) 2003-03-28 2009-02-10 Georgia Tech Research Corporation Multi-band RF transceiver with passive reuse in organic substrates
US7989895B2 (en) 2006-11-15 2011-08-02 Avx Corporation Integration using package stacking with multi-layer organic substrates
US20110193199A1 (en) * 2010-02-09 2011-08-11 International Business Machines Corporation Electromigration immune through-substrate vias
CN102300396A (en) * 2010-06-24 2011-12-28 新光电气工业株式会社 Wiring substrate
US20130169593A1 (en) * 2010-09-08 2013-07-04 Teijin Chemicals Ltd. Touch panel device and display device with touch panel device
US20140225255A1 (en) * 2009-06-02 2014-08-14 Hsio Technologies, Llc Copper pillar full metal via electrical circuit structure
US20170034908A1 (en) * 2015-07-29 2017-02-02 Phoenix Pioneer technology Co.,Ltd. Package substrate and manufacturing method thereof
US20180070458A1 (en) * 2015-06-29 2018-03-08 Samsung Electro-Mechanics Co., Ltd. Multi-layered substrate and method of manufacturing the same
US20190373742A1 (en) * 2018-05-29 2019-12-05 Tdk Corporation Printed wiring board and method for manufacturing the same

Families Citing this family (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6900708B2 (en) * 2002-06-26 2005-05-31 Georgia Tech Research Corporation Integrated passive devices fabricated utilizing multi-layer, organic laminates
JP5000071B2 (en) * 2003-02-26 2012-08-15 新光電気工業株式会社 Semiconductor device substrate and semiconductor device
WO2004093508A1 (en) * 2003-04-18 2004-10-28 Ibiden Co., Ltd. Rigid-flex wiring board
JP4536430B2 (en) * 2004-06-10 2010-09-01 イビデン株式会社 Flex rigid wiring board
JP5006035B2 (en) * 2004-06-11 2012-08-22 イビデン株式会社 Flex rigid wiring board and manufacturing method thereof
JP5295596B2 (en) * 2008-03-19 2013-09-18 新光電気工業株式会社 Multilayer wiring board and manufacturing method thereof
US20100012354A1 (en) * 2008-07-14 2010-01-21 Logan Brook Hedin Thermally conductive polymer based printed circuit board
US8867219B2 (en) 2011-01-14 2014-10-21 Harris Corporation Method of transferring and electrically joining a high density multilevel thin film to a circuitized and flexible organic substrate and associated devices
JP6274135B2 (en) * 2015-03-12 2018-02-07 株式会社村田製作所 Coil module
JP2018032659A (en) * 2016-08-22 2018-03-01 イビデン株式会社 Printed wiring board and method for manufacturing the same
US10813213B2 (en) 2017-02-16 2020-10-20 Azotek Co., Ltd. High-frequency composite substrate and insulating structure thereof
TWI634820B (en) * 2017-07-17 2018-09-01 佳勝科技股份有限公司 Circuit board
US11225563B2 (en) 2017-02-16 2022-01-18 Azotek Co., Ltd. Circuit board structure and composite for forming insulating substrates
US11044802B2 (en) 2017-02-16 2021-06-22 Azotek Co., Ltd. Circuit board
US10869385B2 (en) * 2018-10-30 2020-12-15 Taiwan Semiconductor Manufacturing Company, Ltd. Semiconductor device, circuit board structure and method of fabricating the same
CN111970810A (en) * 2019-05-20 2020-11-20 庆鼎精密电子(淮安)有限公司 Multilayer resin substrate and method for manufacturing same

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5046238A (en) * 1990-03-15 1991-09-10 Rogers Corporation Method of manufacturing a multilayer circuit board
US5103293A (en) * 1990-12-07 1992-04-07 International Business Machines Corporation Electronic circuit packages with tear resistant organic cores
US5451721A (en) * 1990-09-27 1995-09-19 International Business Machines Corporation Multilayer printed circuit board and method for fabricating same
US5888627A (en) * 1996-05-29 1999-03-30 Matsushita Electric Industrial Co., Ltd. Printed circuit board and method for the manufacture of same
US6565954B2 (en) * 1998-05-14 2003-05-20 Matsushita Electric Industrial Co., Ltd. Circuit board and method of manufacturing the same
US6586686B1 (en) * 1997-06-06 2003-07-01 Ibiden Co., Ltd. Multilayer printed wiring board and method for manufacturing the same

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH09199635A (en) 1996-01-19 1997-07-31 Shinko Electric Ind Co Ltd Multilayer film for forming circuit substrate, multilayer circuit substrate using it, and package for semiconductor device
JP3299679B2 (en) 1996-12-27 2002-07-08 新光電気工業株式会社 Multilayer wiring board and method of manufacturing the same
JP2001053198A (en) 1999-08-12 2001-02-23 Shinko Electric Ind Co Ltd Method for manufacturing multilayer wiring board

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5046238A (en) * 1990-03-15 1991-09-10 Rogers Corporation Method of manufacturing a multilayer circuit board
US5451721A (en) * 1990-09-27 1995-09-19 International Business Machines Corporation Multilayer printed circuit board and method for fabricating same
US5103293A (en) * 1990-12-07 1992-04-07 International Business Machines Corporation Electronic circuit packages with tear resistant organic cores
US5888627A (en) * 1996-05-29 1999-03-30 Matsushita Electric Industrial Co., Ltd. Printed circuit board and method for the manufacture of same
US6586686B1 (en) * 1997-06-06 2003-07-01 Ibiden Co., Ltd. Multilayer printed wiring board and method for manufacturing the same
US6565954B2 (en) * 1998-05-14 2003-05-20 Matsushita Electric Industrial Co., Ltd. Circuit board and method of manufacturing the same

Cited By (28)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7260890B2 (en) * 2002-06-26 2007-08-28 Georgia Tech Research Corporation Methods for fabricating three-dimensional all organic interconnect structures
US20040000425A1 (en) * 2002-06-26 2004-01-01 White George E. Methods for fabricating three-dimensional all organic interconnect structures
US20050011670A1 (en) * 2002-12-19 2005-01-20 Endicott Interconnect Technologies, Inc Circuitized substrate assembly and method of making same
US7071423B2 (en) * 2002-12-19 2006-07-04 Endicott Interconnect Technologies, Inc. Circuitized substrate assembly and method of making same
US7805834B2 (en) 2003-03-28 2010-10-05 Georgia Tech Research Corporation Method for fabricating three-dimensional all organic interconnect structures
US7489914B2 (en) 2003-03-28 2009-02-10 Georgia Tech Research Corporation Multi-band RF transceiver with passive reuse in organic substrates
US20060017152A1 (en) * 2004-07-08 2006-01-26 White George E Heterogeneous organic laminate stack ups for high frequency applications
US8345433B2 (en) 2004-07-08 2013-01-01 Avx Corporation Heterogeneous organic laminate stack ups for high frequency applications
US7439840B2 (en) 2006-06-27 2008-10-21 Jacket Micro Devices, Inc. Methods and apparatuses for high-performing multi-layer inductors
US20080000874A1 (en) * 2006-07-03 2008-01-03 Matsushita Electric Industrial Co., Ltd. Printed wiring board and method of manufacturing the same
US20080036668A1 (en) * 2006-08-09 2008-02-14 White George E Systems and Methods for Integrated Antennae Structures in Multilayer Organic-Based Printed Circuit Devices
US7808434B2 (en) 2006-08-09 2010-10-05 Avx Corporation Systems and methods for integrated antennae structures in multilayer organic-based printed circuit devices
US7989895B2 (en) 2006-11-15 2011-08-02 Avx Corporation Integration using package stacking with multi-layer organic substrates
US9930775B2 (en) * 2009-06-02 2018-03-27 Hsio Technologies, Llc Copper pillar full metal via electrical circuit structure
US20140225255A1 (en) * 2009-06-02 2014-08-14 Hsio Technologies, Llc Copper pillar full metal via electrical circuit structure
US8304863B2 (en) * 2010-02-09 2012-11-06 International Business Machines Corporation Electromigration immune through-substrate vias
US9153558B2 (en) 2010-02-09 2015-10-06 International Business Machines Corporation Electromigration immune through-substrate vias
US20110193199A1 (en) * 2010-02-09 2011-08-11 International Business Machines Corporation Electromigration immune through-substrate vias
CN102300396A (en) * 2010-06-24 2011-12-28 新光电气工业株式会社 Wiring substrate
US20130169593A1 (en) * 2010-09-08 2013-07-04 Teijin Chemicals Ltd. Touch panel device and display device with touch panel device
US9189112B2 (en) * 2010-09-08 2015-11-17 Teijin Chemicals Ltd. Touch panel device and display device with touch panel device
US20180070458A1 (en) * 2015-06-29 2018-03-08 Samsung Electro-Mechanics Co., Ltd. Multi-layered substrate and method of manufacturing the same
US10455708B2 (en) * 2015-06-29 2019-10-22 Samsung Electro-Mechanics Co., Ltd. Multilayered substrate and method for manufacturing the same
US20170034908A1 (en) * 2015-07-29 2017-02-02 Phoenix Pioneer technology Co.,Ltd. Package substrate and manufacturing method thereof
US9992879B2 (en) * 2015-07-29 2018-06-05 Phoenix Pioneer Technology Co., Ltd. Package substrate with metal on conductive portions and manufacturing method thereof
US10117340B2 (en) 2015-07-29 2018-10-30 Phoenix Pioneer Technology Co., Ltd. Manufacturing method of package substrate with metal on conductive portions
US20190373742A1 (en) * 2018-05-29 2019-12-05 Tdk Corporation Printed wiring board and method for manufacturing the same
US11382218B2 (en) * 2018-05-29 2022-07-05 Tdk Corporation Printed wiring board and method for manufacturing the same

Also Published As

Publication number Publication date
TW538663B (en) 2003-06-21
US6759600B2 (en) 2004-07-06
KR20020083485A (en) 2002-11-02

Similar Documents

Publication Publication Date Title
US6759600B2 (en) Multilayer wiring board and method of fabrication thereof
CN102612252B (en) Printed wiring board
US8400776B2 (en) Multilayered printed wiring board
US6011694A (en) Ball grid array semiconductor package with solder ball openings in an insulative base
US5994773A (en) Ball grid array semiconductor package
US5478972A (en) Multilayer circuit board and a method for fabricating the same
US7421777B2 (en) Method of manufacturing multilayer wiring substrate using temporary metal support layer
JP2008544512A (en) Circuit board structure and manufacturing method thereof
JP2007227586A (en) Substrate incorporating semiconductor element, and method of manufacturing same
JP2011060875A (en) Electronic component built-in substrate and method of manufacturing the same, and semiconductor device using the substrate
JP2015225895A (en) Printed wiring board, semiconductor package and printed wiring board manufacturing method
JP3299679B2 (en) Multilayer wiring board and method of manufacturing the same
US20050011677A1 (en) Multi-layer flexible printed circuit board, and method for fabricating it
JP2018082084A (en) Printed circuit board and manufacturing method thereof
JP3879158B2 (en) Multilayer printed wiring board and manufacturing method thereof
JP3930222B2 (en) Manufacturing method of semiconductor device
JP3856743B2 (en) Multilayer wiring board
JP2018032661A (en) Printed wiring board and method for manufacturing the same
JP2010258019A (en) Resin multilayered module, and method of manufacturing resin multilayered module
TWI489919B (en) Method for manufacturing wiring board for mounting electronic component, wiring board for mounting electronic component, and method for manufacturing wiring board having an electronic component
JP5245756B2 (en) Circuit board, multilayer circuit board, and method for manufacturing multilayer circuit board
KR100751731B1 (en) Electronic part manufacturing method and base sheet
JP2003198138A (en) Method of manufacturing printed wiring board
JP4994099B2 (en) Manufacturing method of mounting structure
JP2006269466A (en) Printed circuit board and manufacturing method thereof

Legal Events

Date Code Title Description
AS Assignment

Owner name: SHINKO ELECTRIC INDUSTRIES CO., LTD., JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KOYAMA, TOSHINORI;KATAGIRI, NORITAKA;REEL/FRAME:012825/0707

Effective date: 20020412

STCF Information on status: patent grant

Free format text: PATENTED CASE

FEPP Fee payment procedure

Free format text: PAYOR NUMBER ASSIGNED (ORIGINAL EVENT CODE: ASPN); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

FPAY Fee payment

Year of fee payment: 4

FPAY Fee payment

Year of fee payment: 8

FPAY Fee payment

Year of fee payment: 12